Journal of Constructional Steel Research 63 (2007) 475–484

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Resistance of headed studs subjected to fatigue loading

Part I: Experimental study
Gerhard Hanswille ∗ , Markus Porsch, Cenk Ustundag
Institute of Steel and Composite Structures, University of Wuppertal, Germany

Received 13 March 2006; accepted 30 June 2006

Abstract

In steel–concrete composite structures the transfer of longitudinal shear forces at the interface between steel and concrete is mostly realized by
headed shear studs. Especially in bridges due to traffic loads these shear connectors are subjected to high-cycle loading and the fatigue resistance
governs the design. In this first part of two companion papers a series of experimental work with standard EC4 push-out specimens is presented.
The main purpose of these tests was to determine the fatigue life and a possible reduction of the static strength of the headed shear studs subjected
to unidirectional cyclic loading. A further aspect was to examine the effects of the loading sequence and damage accumulation on the fatigue life.
The results of the experimental investigations show that due to a crack initiation at the stud foot at 10%–15% of the fatigue life, an early reduction
of the static strength is caused. Furthermore tests to examine the effects of the loading sequence on the fatigue life revealed that the linear damage
accumulation hypothesis according to Palmgren and Miner on which the present design codes are based do not describe the real behaviour.
c 2006 Elsevier Ltd. All rights reserved.

Keywords: Fatigue life; Push-out test; Steel; Concrete; Composite; Headed shear studs; Unidirectional; Cyclic loading; Reduced static strength; Damage
accumulation

1. Introduction push-out tests to determine the fatigue life of shear connectors.

In recent decades as a result of the benefits of combining
the advantages of its components, steel–concrete composite
beams have seen widespread use in buildings and bridges.
The composite action of the components steel and concrete is
realized by the shear connectors welded on the steel flange.
Because of its economic and fast application headed shear
studs are the most commonly used type of shear connectors in
steel–concrete composite constructions. Especially in bridges
due to traffic actions these studs are subjected to high-cycle
fatigue loading. This is also the case in crane runways and
composite beams used for industrial buildings exposed to traffic
by fork-lift trucks. Because of its costs and difficulties arising
in the interpretation of the results of full-scale beam tests, the
evaluation of the behaviour of the shear studs generally takes
place with standard push-out test specimens. Since the 1960s
various researchers have conducted a great number of cyclic
∗ Corresponding address: University of Wuppertal, Institute of Steel and
Composite Structures, Pauluskirchstrabe 7, 42285Wuppertal, Germany.
E-mail address: hanswill@uni-wuppertal.de (G. Hanswille).
Some of them are given in [1–9]. Maybe one of the remarkable
points in these investigations was that repeated loading causes
a reduction of the static strength of the shear stud within its
lifetime [10]. This is an indication that the design concept in
the current codes [11,12] does not describe the real behaviour,
because the codes assume that ultimate limit states and fatigue
limit states can be verified by independent checks. The design
concept, illustrated in Fig. 1(a), of the before mentioned codes
is based on the evaluation of internationally performed tests
on push-out test specimens to determine the ultimate static
strength and fatigue strength [13–16]. The verification of the
fatigue resistance takes place comparable to steel structures
on the basis of nominal stress concepts and the linear damage
accumulation hypothesis according to Palmgren and Miner [17,
18]. Deterioration in strength of stud shear connectors and
change in loading condition due to the change in deformation
behaviour remain unconsidered which may result in a reduction
of the reliability index so that it may fall below the target values
in codes as illustrated in Fig. 1(b).
So far, except for the test conducted by Oehlers [19],
there weren’t enough tests where the reduced static strength

c 2006 Elsevier Ltd. All rights reserved.

0143-974X/$ - see front matter
doi:10.1016/j.jcsr.2006.06.035
476 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484

accumulation hypothesis will be discussed in the companion

Notation paper.
AD fatigue fracture area of the shear stud
AG forced fracture area of the shear stud 2. Push-out tests
Ec secant modulus of elasticity of concrete
N number of load cycles 2.1. Test program
Nf fatigue life
Pmax peak value of cyclic loading The experimental program consists of a total of 6 series
Pu,0 ultimate static strength of the shear stud (S1–S6). The first four series S1–S4 deal with constant
Pu,N reduced static strength of the shear stud after N amplitude tests where the effect of unidirectional cyclic loading
load cycle on the static strength and the fatigue life of the push-out
Vx coefficient of variation specimen were investigated with varying loading parameters,
fc cylinder compressive strength of concrete peak load Pmax and loading range 1P. In each series initially
1P range of the cyclic loading three static tests were performed to determine the mean value
δi inelastic displacement at ith load cycles of the ultimate static load P̄u,0 of the push-out specimen. The
δ1 plastic slip at the first cycle mean value of the ultimate static load represents the reference
parameter for the relative values of loading parameter required
for cyclic tests. Using the relative loading parameters, three
load controlled cyclic tests were performed to determine the
after high-cycle preloading was systematically investigated.
mean fatigue life N̄ f of the push-out specimen. Subsequently
Thus in the light of the information gained from previous
six cyclic tests were conducted for approximately 30% and 70%
researches a comprehensive program of 71 push-out tests
of the mean fatigue life N̄ f . After reaching the corresponding
was developed to determine the reduced static strength after number of cycles each of these six test specimens was statically
high-cycle preloading and to examine the effects of the loaded to failure under displacement control to obtain the
loading sequence and damage accumulation on the fatigue reduced static strength after high cycle preloading. The chosen
life. This paper deals with the results of the experimental loading parameters and number of performed tests for the first
studies on the behaviour of headed shear studs subjected to four series are summarized in Table 1.
unidirectional cyclic loading. Development of semi-empirical Based on the results of the constant amplitude tests in
analytical methods to determine the reduced static strength and the series S5 and S6 tests with the two and four blocks
the fatigue life and the development of an improved damage loading sequences were performed in which the peak load was

Fig. 1. (a) Safety concept to determine the lifetime of composite structures subjected to high cycle loading according to present codes; (b) actual influence of high
cycle loading on lifetime.
 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484 477

Fig. 2. Tests with multiple blocks of loading (a) two blocks; (b) four blocks.

Table 1 The mean height of the weld collars was 8.4 mm and the
Summary of the single level tests mean diameter 28.9 mm. The height of the welded stud was
Series 1P/ P̄u,0 Pmax / P̄u,0 Number of tests 125 mm. For casting the steel beams were cut into two halves
P̄u,0 N̄ f N ∼ 0.3 N̄ f N ∼ 0.7 N̄ f and the concrete slabs were cast horizontally. The steel flanges
were greased prior to casting to remove friction between the
S1 0.20 0.44 3 3 3 3
S2 0.25 0.71 3 3 3 3 concrete and steel. The two halves were subsequently welded
S3 0.25 0.44 3 3 3 3 together. This test specimen complies with the standard push-
S4 0.20 0.71 3 3 3 3 out specimen according to Eurocode 4 with an exception of
S5E 0.25 0.30 3 1 1 1 lateral restraints of the concrete slabs at the specimen bottom.
The lateral restraints avoid especially in the lower row of shear
studs the introduction of additional tensile forces resulting from
Table 2
Summary of the tests with multiple blocks of loading the moment of eccentricity and enable a better simulation of
the real behaviour in composite beams. Details of the push-out
Series Number of tests 1P/ P̄u,0 Pmax / P̄u,0
specimens are given in Fig. 3.
Block 1 Block 2 Block 3 Block 4
S5-2 3 0.71 0.44 – –
2.3. Test setup and loading procedure
S5-3 1 0.44 0.71 – –
0.25
S5-4 4 0.44 0.30 – –
S5-6 4 0.30 0.44 – – Cyclic and monotonic loading was applied by a 2500 kN
S6-3 3 0.44 0.54 0.64 0.74 servo hydraulic actuator. The load was introduced into the steel
0.20
S6-4 3 0.74 0.64 0.54 0.44 beam by means of a head plate welded on the cross section
of the beam. The actuator was controlled by an Instron 8800
increased or decreased subsequently while the loading range controller which allowed load and displacement control, and
was held constant (see Fig. 2 and Table 2). had sinusoidal control waveforms which were utilized for the
Like the constant amplitude tests the series S5 and S6 were cyclic testing. Displacement control was used for the monotonic
initiated with short-time static tests to determine the ultimate tests, and load control was used for all cyclic testing. The test
static load. During the tests with multiple blocks of loading setup used in the experiments is shown in Fig. 4.
it appeared necessary to perform further constant amplitude The monotonic tests were conducted at a displacement
tests with a not investigated low peak load (Pmax / P̄u,0 = rate of 0.004 mm/s. The time taken to reach the ultimate
0.3). Thus, 3 complementary constant amplitude cyclic tests load was typically of the order of 50 min. After reaching
(referred as series S5E) were performed in these series. The the ultimate load the displacement rate was increased up to
chosen loading parameters and number of performed tests for 0.008 mm/s. Cyclic tests were conducted with a load frequency
tests with multiple blocks of loading are summarized in Table 2. of 3 Hz. In order to collect data about the stiffness and
plastic deformation, cyclic tests were held after a specific
2.2. Test specimens number of cycles and the specimens were released and reloaded
monotonically. During the tests the time, load from the actuator
The specimen used in the push-out tests consists of a load cell, ram displacement from the built-in transducer in the
650 mm long HEB260 profile and two 650 mm long, 600 mm actuator, longitudinal displacement between the concrete slab
wide and 150 mm thick concrete slabs. The slabs are connected and steel beam and uplift of the slabs were measured. The ram
to the steel beam by means of four headed shear studs of displacement included movement due to the compliance of the
22 mm diameter welded on each side of the beam. The weld test rig, and therefore it was not used in any subsequent data
collars complied with the requirements of EN ISO 13918 [20]. analysis. The longitudinal displacements were measured by two
478 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484

Fig. 3. Details of the push-out test specimen.

Table 4
Average test results per stud
P̄u, N̄ N̄1 P̄u, N̄ N̄2
Series P̄u,0 N̄ f (–) P̄u, N̄ 1 P̄u, N̄ 2
1 P̄u,0 N̄ f 2 P̄u,0 N̄ f
(–) (kN) (kN) (–) (–) (kN) (–) (–)
S1 205 6.2 × 106 154 0.75 0.32 129 0.63 0.90
S2 184 1.2 × 106 174 0.95 0.32 154 0.84 0.70
S3 201 5.1 × 106 133 0.66 0.24 123 0.61 0.69
S4 181 3.5 × 106 181 1 0.29 156 0.86 0.72
S5E 189 6.4 × 106 111 0.59 0.19 114 0.60 0.73

The structural steel beams of HEB 260 section with the material
quality S235 J2G3 were used in each test. From the tensile tests
the mean yield strength and ultimate stress were determined
Fig. 4. Test setup and the hydraulic actuator. as 337 N/mm2 and 448 N/mm2 , respectively. The modulus
of elasticity of the beam was 209 341 N/mm2 . Stud shear
Table 3 connectors, which were welded automatically onto the steel
Mean values of material properties of concrete beam flange, had a material quality of S235 J2G3+C450. Based
Series on the tensile tests, the yield strength and the ultimate tensile
S1 S2 S3 S4 S5 S6 strength of the connectors were determined as 440 N/mm2
f c (N/mm2 ) 44–52 42–45 53–56 43 43 46
and 528 N/mm2 , respectively. The modulus of elasticity of
E cm (N/mm2 ) 36 400 36 400 39 000 33 900 33 500 33 700 the studs was 216 351 N/mm2 . As reinforcing steel, standard
deformed bars with diameters of 10 mm and 12 mm were
used in the concrete slabs. Four tensile tests were performed
LVDT’s on each steel flange to which the studs were welded on each bar sample. The average yield strength and ultimate
(see Fig. 4). strength was obtained as 549 N/mm2 and 606 N/mm2 for
the bars of 10 mm, and 501 N/mm2 and 561 N/mm2 for the
2.4. Material properties bars of 12 mm, respectively. The modulus of elasticity of the
bars with diameters of 10 mm and 12 mm were determined as
At various intervals during the curing process at 28 days 197 779 N/mm2 and 204 540 N/mm2 , respectively.
as well as at the beginning, in the middle and at the end
of each series cylinder compression tests were carried out 3. Results of the constant amplitude tests
to determine the compressive cylinder strength and elastic
stiffness of the concrete. Standard cylinders of 150 mm in Table 4 shows the results of the static strength, the fatigue
diameter and 300 mm in length were used. Table 3 presents the life N̄ f and the reduced static strength after high cycle
range of the mean concrete strength and the mean modulus of preloading for series S1–S5E. The limit state of fatigue is
elasticity associated with the test start for each series according given, when the reduced strength has reached the value of the
to EN 206-1 [21]. peak load. Because of different static strength within each test
In all series structural steel beams, headed shear studs and series the absolute values of Pmax and 1P differ slightly. All
reinforcing bars used in the tests were from the same batch. data given in Table 4 represent generally the mean values of
 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484 479

Fig. 5. Comparison of Pe –Pt of the static tests (Pu,0 ) in series S1–S6 with the Pe –Pt data of the model of Eurocode 4.

three similar tests. The strength data are based on short time
behaviour, so when relaxation must be taken into account, it is
necessary to reduce the values by 10%. In contrast to series S2
and S4 the low peak loads in series S1, S3 and S5E led to very
high fatigue lives N̄ f .
Fig. 5 shows the comparison of static tests results (Pe )
for series S1–S6 with the corresponding data of theoretical
shear resistance (Pt ) according to the empirical model of
Eurocode 4 [15]. The resistance is given by the minimum of
two equations, which describe the shear resistance in the case
of “shear failure of the stud” and “failure of the concrete”,
respectively. This model is based on the assumption, that in
case of low concrete strength the shear resistance is determined
only by the failure of concrete in the lower part of the shank. Fig. 6. Comparison of fatigue test results with the prediction in Eurocode 4.
In the case of high concrete strength it is assumed, that the
shear resistance is determined by the shear resistance of the stud increase in the plastic slip with the number of cycles while in
shank. The results of the static tests are in good agreement with the remaining part of the lifetime a nearly linear increase of the
the prediction of the theoretical model, on which the design plastic slip occurs with the number of cycles.
rules in Eurocode 4 are based. The mean value of the initial plastic slip δ 1 in the first cycle
In Fig. 6 the results of the fatigue tests of series S1–S5E are is in series with high peak loads approximately 8 times greater
compared with the corresponding test results, from which the than in series with low peak loads.
fatigue strength curve in Eurocode 4 was derived.
3.2. Static strength versus lifetime
The test results are in good agreement with the given
prediction according to Eurocode 4. The influence of the cyclic loading becomes evident, when
the static strengths are plotted versus number of load cycles.
3.1. Plastic slip—load cycles This is shown in Fig. 8, where the results are related to the
mean static strength and the mean fatigue life of each series
In case of cyclic loading the load–deformation behaviour respectively. Especially in series S1, S3 and S5E with low peak
is characterized by an increasing plastic slip and a decreasing loads the rapid decrease of the static strength within the first
elastic stiffness K el . In Fig. 7 the inelastic slip δi related to the 20% of the fatigue life is noteworthy. On the other hand N̄ f is
plastic slip in the first cycle δ1 is plotted against the number much greater than for the series with high peak loads.
of cycles over the fatigue life N̄i / N̄ f for series S1–S4. The The reduction of the static strength over the lifetime is
beginning and the end of the lifetime are associated with a steep considered in four stages. In stage I there is no significant
480 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484

Fig. 7. Plastic slip over the fatigue life in series S1–S4.

Fig. 8. Decrease of static strength versus lifetime due to high cycle loading.

damage in concrete and steel and therefore no reduction. In with the number of cycles. In Fig. 8 the coefficient of variation
stage II and stage IV there is an instable reduction of the static Vx of the static strengths gained from three similar tests is
strength. Stage III shows a linear variation of the static strength marked out exemplarily for the series S4. The scatter of the
 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484
Fig. 9. Preparation stages for examination purposes.
results increases with the degradation of the strength of the
shear studs. Comparison of the series with the same load range
and different peak load makes clear that the static strength and
the fatigue life are affected not only from the load range but
also from the peak load of the cyclic loading. Furthermore it is
also obvious that for the same amount of change the effect of
the load range on the static strength is much greater than on the
peak load.
3.3. Failure modes
To investigate the reasons for the reduction of the static
strength, the concrete slabs were separated from the steel beam
and the fractured surfaces at the foot of each headed stud were
examined. Fig. 9 gives in detail the stages of preparation of
the test specimens after each push-out test for examination
purposes. Also in some cases metallurgical investigations were
carried out.
The examined fracture surfaces consist of the typical dull
fatigue fracture and bright forced fracture zones, where in the
fatigue tests the former one is formed by cracks propagating to
a critical length and the second one due to forced shear fracture.
Furthermore the tests reveal two failure modes, which closely
correlate with the peak load Pmax . For high peak loads such as
in series S2 and S4 only mode A (see Fig. 10) occurs. For lower
peak loads such as in series S1, S3, S5E in most cases mode B
occurs, even though it must be mentioned, that in some cases
both mode A and mode B were detected at the same time at
one stud foot. This means, that there were formed two cracks
and both could initiate forced fracture. Investigation of the
microstructure reveals that both points, P1 and P2, show high
481
geometrical and metallurgical notch effects due to the welding
technique. Furthermore the short time static tests carried out
after high cycle preloading show in case of mode B more ductile
behaviour than mode A, which is in good agreement with both
crack forms.
The fractured surfaces at the stud feet in case of failure mode
A show typical arrest lines, so that it was possible to detail
the crack development for this mode. Unfortunately for mode
B there couldn’t be observed any stop marks except for one
test specimen although the testing procedure was always the
same. The evaluation of the test results as yet showed that for
mode A (series S2 and S4) and mode B (series S1, S3 and S5E)
there is a linear relationship between the reduced static strength
and the size of the fatigue cracking zone. This relationship is
illustrated in Fig. 11 schematically, where A D is the area of
the fatigue cracking zone and A G the area of the forced shear
fracture. In case of mode A the whole fracture area (A D + A G )
corresponds to the stud area. In case of mode B the whole
fracture area is much larger than the stud area. The coefficient of
correlation of the linear relationship is 0.99 for mode A and 0.85
for mode B. If the analysis is based on all tests of mode A and
B, a coefficient of 0.88 results (Fig. 11). From the given linear
correlations can be deduced that the crack propagation in the
shear stud has approximately 60% attribution in the reduction
of the static strength.
4. Results of tests with multiple blocks of loading
The results of the two and four blocks loading sequences (see
Fig. 2) are given in Tables 5 and 6 respectively. The mean value
of the reference ultimate static strength P̄u,0 of the shear studs
482 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484

Fig. 10. Failure modes A and B.

Fig. 11. Relationship between reduced static strength and fatigue fracture area.

is 186 kN for the tests with two blocks of loading in series S5
and 196 kN for the tests with four blocks of loading in series S6.
It is to be noticed that in tests with multiple blocks of loading
the failure of the shear studs can occur on the one hand during
the cyclic loading by the decrease of static strength to the peak
load and on the other during switching to the next block with
a higher peak load by exceeding the reduced static strength.
A typical example for the last case occurred in the test S5-3a
during switching to the second block with a peak load of 133 kN
by exceeding the reduced static strength of 124 kN per stud.
Evaluation of the tests with multiple blocks of loading on
the basis of the linear damage accumulation hypothesis of
Palmgren and Miner, on which the present design codes rely,
is shown in Fig. 12. The fatigue life Nfi corresponding to each
block of cyclic loading is gained from the results of the constant
amplitude tests of series S1–S4 and S5E. The missing values of
number of cycles to fatigue for the blocks 2 and 3 in the test
with four blocks of loading are determined by means of a linear
interpolation from the results of series S1 and S4. Thus, for the
peak loads of 101 kN and 120 kN per stud the fatigue life N f
 G. Hanswille et al. / Journal of Constructional Steel Research 63 (2007) 475–484 483

Table 5
Loading parameters and results of the tests with two blocks of loading (series S5)

Test (–) Block 1 Block 2 N1 + N2 (×106 )

Pmax,1 (kN) 1P (kN) N1 (×106 ) Pmax,2 (kN) 1P (kN) N2 (×106 )
S5-2a 133 0.204 83 0.792 0.996
S5-2c 133 0.198 83 1.440 1.638
S5-3a 83 1.099 133 – 1.099
S5-4a 83 0.473 56 1.365 1.838
S5-4b 83 0.517 56 0.772 1.289
S5-4c 83 47 0.544 56 47 0.735 1.2791
S5-4d 83 0.542 56 3.396 3.938
S5-6a 56 0.537 83 5.821 6.358
S5-6b 56 1.223 83 0.761 1.984
S5-6c 56 1.295 83 1.744 3.039
S5-6d 56 1.277 83 3.206 4.483

Table 6
Loading parameters and results of the tests with four blocks of loading (series S6)
P4
Test 1P Block 1 Block 2 Block 3 Block 4 6
i=1 Ni (×10 )
(–) (kN)
Pmax,1 N1 Pmax,2 N2 Pmax,3 N3 Pmax,4 N4
(kN) (×106 ) (kN) (×106 ) (kN) (×106 ) (kN) (×106 )
S6-3a 38 83 0.756 101 0.768 120 0.770 139 0.868 3.162
S6-3b 38 83 0.765 101 0.804 120 0.785 139 0.324 2.678
S6-3c 38 83 0.754 101 0.759 120 0.750 139 0.449 2.712
S6-4a 38 139 0.550 120 0.763 101 0.754 83 0.583 2.650
S6-4b 38 139 0.550 120 0.758 101 0.750 83 0.756 2.815
S6-4c 38 139 0.540 120 0.753 101 0.753 83 1.208 3.254

5. Summary and conclusions

A total of 71 push-out tests was performed to determine

the reduced static strength after high-cycle preloading and to
examine the effects of the loading sequence on the fatigue
life. The test results, especially the observation of arrest lines,
indicate an early crack initiation in approximately 10%–20% of
the fatigue life which causes the reduction of the static strength.
Constant amplitude tests have shown that the magnitude of the
peak load Pmax of the cyclic loading has a significant effect
on the crack form occurring at the stud foot. Evaluation of
the tests with multiple block loading sequences on the basis of
the linear damage accumulation according to Palmgren–Miner
yields unsafe results. Development of analytical methods to
determine the reduced static strength and the fatigue life and the
development of a modified damage accumulation hypothesis
will be discussed in the companion paper.

Fig. 12. Comparison between the test results with the results of the lifetime
prediction according to Palmgren–Miner.
is determined as 5.3 × 106 and 4.4 × 106 number of cycles,
respectively.
It is obvious that except for one test in Fig. 12 all results of
the lifetime prediction according to Palmgren and Miner lie on
the unsafe side. The main reason for this is the omission of the
effects due to crack propagation in the shank of the stud and the
increasing local crushing of concrete surrounding the stud weld.
Acknowledgement
The experimental program described in this paper is financed
by the German Research Foundation (DFG) within the scope of
Collaborative Research Centre 398.
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Gerhard Hanswille, Prof. Dr.-Ing. Since 1992 Professor for Steel and
Composite Structures at the University of Wuppertal, Germany. Chairman of
the German Standard Committee for Composite Structures and member of
the Project Team for Eurocode 4 Part 1-1 and Part 2. Senior partner of HRA
consulting engineers in Bochum, Germany and involved in composite and steel
bridge and building design.
Markus Porsch, Dipl.-Ing. Since 2000 assistant at the Institute for Steel and
Composite Structures at the University of Wuppertal, Germany. International
Welding Engineer (IWE).
Cenk Ustundag, M.Sc. Since 2002 doctoral candidate at the Institute for Steel
and Composite Structures at the University of Wuppertal, Germany. Holder of
the German Academic Exchange Service (DAAD) Research Grant for Doctoral
Candidates since 2003.